Box with multi-ply base panel and method of constructing same

ABSTRACT

A box part is provided with an eight panel base and sides reinforced with a four-sided, open bottom insert. The box part is constructed by forming a planar four panel subassembly and a tray-like subassembly having four panels and side sections, from a single blank. The insert is received within the tray-like subassembly. The planar subassembly is then folded over the side of the insert and placed into the tray-like subassembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A “SEQUENCE LISTING”, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a box part fabricated from a paperboard, fiberboard or plastic sheet blank folded to form the bottom or top of a package for a consumer product or the like and more particularly to such a box part that includes a multi-ply base panel and a separate open bottom, side reinforcing insert for providing increased strength and resistance to twisting or torque, and to a method of constructing same.

2. Description of Prior Art

Boxes formed of paperboard, fiberboard or plastic material are well known in the art for use in packaging many different types of products. Such boxes often include a tray-like bottom box part, including a planar base panel with perpendicular sides, which is designed to contain the product. The product may be nested in a recess in a vacuum formed or molded plastic insert adapted to received in the bottom box part. The plastic from which the product containing insert is made may be opaque, clear or flocked. A cover, in the form of a top box part of similar construction, or in the form of a rigid, opaque or clear top, may be used over the bottom box part to fully enclose the product.

Such box parts are commonly formed from a die-cut planar blank that includes a rectangular base panel with four edges. Joined to each of the four panel edges is a side section. Each side section consists of an inner and outer wall. The side section walls are joined along a fold line that will become the edge of the side section.

The box part is constructed by folding each of the outer walls along the panel edge into a plane perpendicular to the base panel. Each of the inner walls is then folded along the fold line into side-by-side relation with the interior surface of the outer wall. Webs may be provided between the outer walls of the side sections. Each of the webs has two sections divided by a fold line. The sections of the webs are folded together and are glued to each other to fix the side sections in place.

In some cases, tabs extending outwardly from the sides of the inner walls are provided. Extensions protruding from the unattached edge of the inner walls may also be provided instead of, or in addition, to the webs. Those tabs and/or extensions are glued to adjacent surfaces to enhance the strength of the box part.

It is also known to incorporate a separate, pre-assembled, closed-bottom tray-like insert into the box part to further increase its strength and rigidity. The insert is formed from a paper or cardboard blank to include a rectangular base panel, approximately the same size and shape as the base panel of the box part. Sides extend from each of the four edges of the base panel of the insert. The sides of the insert are folded into upright positions relative to the base panel of the insert and secured to each other by webs or tabs to form a tray.

The insert is placed over the box part blank, with the base panel of the insert aligned with the base panel of the box part. The side sections of the box part are erected and fixed in place as explained above, with the sides of the insert situated within the recesses defined between the inner and outer walls of the side sections of the box part.

The resulting box part has a two-ply base panel and reinforced sides. As compared to a box part with a single-ply base panel and unreinforced side sections, it is stronger and more resistant to twisting force. However, for some applications, the strength and twisting force resistance of the box part with a two-ply base panel and reinforced sides is still insufficient.

Further, the “perceived value” of the packaged product is an important marketing issue. In that regard, it is important that the box part have a straight and smooth appearance, be capable of accepting surface markings well and exhibit great weight or heft. It is also desirable that there be as little gapping of the sides or corners of the box part as is possible.

It is, therefore, a prime object of the present invention to provide a box part with a multi-ply base panel and a separate open bottom insert that has increased strength and resistance to twisting or torquing force.

It is another object of the present invention to provide a box part with an eight-ply base panel.

It is another object of the present invention to provide a box part with a multi-ply base panel and reinforcing side insert that is straight, smooth, capable of accepting surface markings well and has little or no gapping at the sides or corners.

It is another object of the present invention to provide a box part with a multi-ply base panel which is constructed by forming a planar subassembly and a tray-like subassembly from a single blank and then placing the planar subassembly into the tray-like subassembly.

It is another object of the present invention to provide a box part with a multi-ply base panel and a reinforcing insert wherein the insert is simple and inexpensive to construct because it consists of sides with an open bottom.

It is another object of the present invention to provide a method of constructing a box part with a multi-ply base panel and a separate open bottom reinforcing insert.

BRIEF SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a box part is provided including a first panel having first, second, third and fourth edges. Second, third, and fourth panels each having an edge are also provided. A fifth panel is provided with first, second, third and fourth edges. Sixth, seventh and eighth panels are provided, as are first, second, third and fourth side sections. The edge of the second panel is connected to the first edge of the first panel by the first side section. The edge of the third panel is connected to the second edge of the first panel by the second side section. The edge of the fourth panel is connected to the third edge of the first panel by the third side section. The edge of the fifth panel is connected to the fourth edge of the first panel by the fourth side section. The sixth panel is connected to the second edge of the fifth panel. The seventh panel is connected to the third edge of the fifth panel. The eighth panel is connected to the fourth edge of the fifth panel.

Each of the side sections includes inner and outer walls situated in side-by-side section to define a recess therebetween. A separate insert is provided. The insert has four sides and an open bottom. Each of the insert sides is received in the recess defined by a different one of the box part side sections.

Means are provided for fixing the fourth panel to the third panel. Means are provided for fixing the sixth panel to the fifth panel. Means are provided for fixing the seventh panel to the sixth panel. Means are provided for fixing the eighth panel to the seventh panel.

Preferably, each of the panels has approximately the same shape and dimensions. All of the panels are situated in parallel, face-to-face relation, to form the multi-ply base panel of the box part.

Webs are provided connecting the outer walls of the box part side sections. The webs each include first and second web sections. Means are provided for fixing the web sections of each of the webs to each other.

In accordance with another aspect of the present invention, a box part is provided including eight generally rectangular panels situated in substantially face-to-face relation forming the base of the box part. Four interconnected side sections extend from the base in directions generally perpendicular to the plane of the base. Each of the side sections is formed of inner and outer side-by-side walls defining a recess therebetween. A separate four sided, open bottom insert is provided. The sides of the insert are received within the recesses defined between the walls of the side sections.

In accordance with another aspect of the present invention, a method of constructing box part from a blank is provided. The method begins by forming a planar subassembly of multiple panels and forming a tray-like subassembly having a base and side sections. The planar subassembly is then placed into the tray-like subassembly.

An open bottom, four-sided insert is formed. Each of the side sections of the tray-like subassembly defines a recess. The insert is received within the side section recesses.

The tray-like subassembly is formed of multiple base panels. The base panels are placed in face-to-face relation.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS

FIG. 1 is an elevational view of a blank of the unassembled box part of the present invention, showing the first step in the construction process.

FIG. 2 is a view similar to FIG. 1, showing the second step in the construction process.

FIG. 3 is a view similar to FIG. 1, showing the third step in the construction process.

FIG. 4 is a view similar to FIG. 1, showing the completion of the planar subassembly.

FIG. 5 is an elevational view of a blank from which the insert is formed.

FIG. 6 is an isometric view of the constructed insert.

FIG. 7 is an isometric view of the partially constructed box part and the insert, prior to the insert being received in the partially constructed box part.

FIG. 8 is an isometric view similar to that of FIG. 7, showing the partially constructed of the box part with the insert in place, and the first step in the construction of the tray-like subassembly.

FIG. 9 is an isometric view similar to that of FIG. 8, showing the second step in the construction of the tray-like subassembly.

FIG. 10 is an isometric view similar to that of FIG. 8, showing the third step in the construction of the tray-like subassembly;

FIG. 11 is an isometric view similar to that of FIG. 8 showing the planar subassembly being situated in the tray-like subassembly to complete the construction process.

FIG. 12 is an isometric view of the fully constructed box part.

DETAILED DESCRIPTION OF THE INVENTION

The blank from which the main portion of the box part of the present invention is constructed is cut from a paperboard, fiberboard or plastic sheet material so as to have the configuration illustrated in FIG. 1. The blank is provided with a plurality of fold lines defining different portions of the box part. As set forth in detail below, the portions of the blank are folded along the fold lines and fixed to form a box part for use as the bottom of a box, or the top of a box, or both.

The portions of the blank include eight generally rectangular panels 20, 22, 24, 26, 28, 60, 64 and 68. When assembled, those panels will form the base of the box part. All of the panels are preferably square and have substantially the same dimensions.

Panel 20 has four edges 30, 32, 34 and 36, each defining a fold line. A portion of the blank that will become a side section of the box part is interposed between each edge of panel 20 and the panel connected thereto.

Specifically, side section 40 is interposed between edge 30 of panel 20 and edge 50 of panel 22. Side section 42 is interposed between edge 32 of panel 20 and edge 52 of panel 24. Side section 44 is interposed between edge 34 of panel 20 and edge 54 of panel 26. Side section 46 is interposed between edge 36 of panel 20 and edge 56 of panel 28. Edges 50, 52, 54 and 56 constitute fold lines.

Panel 60 is connected to panel 28 along edge 62. Panel 64 is connected to panel 28 along edge 66. Panel 68 is connected to panel 28 along edge 70. Edges 62, 66 and 70 constitute fold lines.

The box part of the present invention is constructed in three basic operations. The first operation, as illustrated in FIGS. 1-4, includes the formation of a planar subassembly. The planar subassembly consists of four panels 28, 60, 64 and 68 situated in face-to-face relation. As illustrated in FIGS. 7-11, a tray-like subassembly is formed by panels 20, 22, 24 and 26, and the associated side sections. A separate insert, illustrated in FIG. 6, is employed to reinforce the tray-like subassembly prior to placing the planar subassembly into the tray-like subassembly.

The first step in the construction of the planar subassembly is to fold panel 60 along fold line 62 such that it is in face-to-face relation with panel 28, as shown by the arrow in FIG. 1. Panel 60 is then glued to panel 28 in that position.

Next, panel 64 is folded along fold line 66 into face-to-face relation over panel 60, as shown by the arrow in FIG. 2. Panel 64 is glued to the panel 60 in that position.

As shown by the arrow in FIG. 3, panel 68 is then folded along line 70 into face-to face relation with panel 64. Panel 68 is glued to panel 64 in that position. The planar subassembly formed of panels 28, 60, 64 and 68 is now complete, as shown in FIG. 4.

FIG. 5 shows the blank form which a separate insert 80 is formed. Insert 80 has four equal sides 82, 84, 86 and 88. Insert 80 is assembled into a four-sided structure, with an open bottom 90, by gluing the unattached edge of side 82 to the unattached edge of side 88.

The insert 80, with open bottom 90, is shown in FIG. 6. As illustrated in FIG. 7, the insert is placed over panel 20 to complete the second portion of the construction operation.

Next, the tray-like subassembly is constructed. As seen by the arrow in FIG. 8, side section 40 is folded over side 88 of insert 80 such that panel 22 is in face-to-face relation with panel 20. This is accomplished by folding the outer wall 94 of side 40 along edge 30 and folding the inner wall 92 of side 40 into position adjacent the interior of insert wall 88. Panel 22 is not glued to panel 20 to avoid any glue marks on the exterior of panel 20.

Webs 96 and 98 are situated between outer wall 94 of side section 40 and outer walls 116 and 122 of the adjacent side sections. Each web is formed by two sections divided by a fold line. The sections of the web 96 and the sections of web 98 are each folded together and glued to each other at the appropriate time to fix the side sections in place. Further, tabs 100 and 102 are provided at either end of inner wall 92. Those tabs are glued to the interior walls of the adjacent side sections, when same are in place.

As seen by the arrow in FIG. 9, panel 24 is folded over side 84 of insert 80 such that panel 24 is in face-to-face relation with panel 22. This is accomplished by folding inner wall 104 of side section 42 along edge 32 and folding the outer wall 106 of side section 42 into position adjacent the interior of insert wall 84. The outer wall 104 of side 42 will be situated adjacent the exterior of insert wall 84. The sections of each of the webs 108 and 110 are folded together and glued to each other at the appropriate time. Tabs 112 and 114 extending from opposite sides of wall 106 are also glued in place. No glue is used between panel 24 and panel 22.

Next, as seen by the arrow in FIG. 10, side section 44 is folded over side 82 of insert 80 such that panel 26 is situated in face-to-face relation with panel 24. This is accomplished by folding side section 44 along fold line 34 such that inner wall 114 is positioned adjacent the interior of insert wall 82. The outer wall 116 of side section 44 is situated adjacent the exterior of insert wall 82. The sections of web 108 are folded together and glued to each other. Further, a layer of glue is situated between panel 24 and panel 26. This completes the construction of the tray-like subassembly, as seen in FIG. 11.

The last step in the construction of the box part is to fold the previously constructed planar subassembly, formed of panels 28, 60 64 and 68, over side 86 of insert 80 such that panel 68 is situated in face-to-face relation with panel 26. This is accomplished by folding the outer wall 122 of side section 46 along edge 56 such that it is in side-by-side relation with the exterior of side 86 of insert 80 and folding inner wall 120 into a position adjacent the interior of side 86. The sections of the webs between side section 46, and adjacent side sections 40 and 42, are then folded together and glued to each other. Tabs 100 and 114 are glued to side 86 of insert 80 to complete the box part, as seen in FIG. 11. The fully constructed box part appears as illustrated in FIG. 12.

It will now be appreciated that the box part of the present invention has eight-ply base panels, as well as four reinforced side sections. The result is a stronger and more twist resistant box part than is possible with previously known constructions. The box part of the present invention is also very smooth, accepts surface markings well and exhibits little or no gapping in the sides or corners. Further, the box part of the present invention costs little or no more to construct than those in the prior art.

While only a single preferred embodiment of the present invention has been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of these modifications and variations that fall within the scope of the present invention, as set forth in the following claims: 

1. A box part comprising a first panel comprising first, second, third and fourth edges, a second panel comprising an edge, a third panel comprising an edge, a fourth panel comprising an edge, a fifth panel comprising first, second, third and fourth edges, a sixth panel, a seventh panel, an eighth panel, and first, second, third and fourth side sections, said edge of said second panel being connected to said first edge of said first panel by said first side section, said edge of said third panel being connected to said second edge of said first panel by said second side section, said edge of said fourth panel being connected to said third edge of said first panel by said third side section, said edge of said fifth panel being connected to said fourth edge of said first panel by said fourth side section, said sixth panel being connected to said second edge of said fifth panel, said seventh panel being connected to said third edge of said fifth panel and said eighth panel being connected to said fourth edge of said fifth panel.
 2. The box part of claim 1 wherein each of said side sections comprises inner and outer walls which when situated in side-by-side relation define a recess therebetween.
 3. The box part of claim 2 further comprising a separate insert adapted to be received within said side section recesses.
 4. The box part of claim 3 wherein said insert comprises four sides and an open bottom.
 5. The box part of claim 4 wherein each of said insert sides is received in the recess defined by a different one of said box part side sections.
 6. The box part of claim 1 further comprising means for fixing said fourth panel to said third panel.
 7. The box part of claim 1 further comprising means for fixing said sixth panel to said fifth panel.
 8. The box part of claim 7 further comprising means for fixing said seventh panel to said sixth panel.
 9. The box part of claim 7 further comprising means for fixing said eighth panel to said seventh panel.
 10. The box part of claim 1 wherein each of said panels has approximately the same shape and dimensions.
 11. The box part of claim 1 wherein all of said panels are situated in substantially parallel, face-to-face relation.
 12. The box part of claim 1 further comprising webs connecting said outer walls of said box part side sections.
 13. The box part of claim 12 wherein each of said webs comprises first and second web sections.
 14. The box part of claim 13 further comprising means for fixing said web sections of each of said webs to each other.
 15. A box part comprising eight generally rectangular panels situated in substantially face-to-face relation forming the base of the box part, four interconnected side sections extending from said base in directions generally perpendicular to the plane of said base, each of said side sections being formed of inner and outer side-by-side walls defining a recess therebetween and a separate, four-sided, open bottom insert, said insert sides being received within the recesses defined between said walls of said side sections.
 16. A method of constructing a box part from a blank, said method comprising the steps of: forming a planar subassembly of multiple panels from one portion of the blank; forming a tray-like subassembly comprising a base and side sections from another portion of the blank; and placing the planar subassembly into the tray-like subassembly.
 17. The method of claim 16 further comprising the step of forming an open bottom, four sided insert.
 18. The method of claim 17 wherein each of said side sections defines a recess and further comprising the step of receiving the insert within the side section recesses.
 19. The method of claim 16 wherein the step of forming the tray-like subassembly comprises the step of forming the tray-like subassembly of multiple base panels by placing the base panels in face-to-face relation. 